Instrumentation Maintenance Fundamentals MODULE 1 ENGR. RENDELL JASON M. LAGMAN ELEMENTS of the INSTRUMENT LOOP • • • • Process Measuring Element Receiving Element Final Control Element Disturbances PV MV PROCESS Final Control Element CO SP Receiving Element Measuring Element PV Maintenance What is Maintenance? All actions necessary for retaining an item, or restoring to it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification. Keep system’s equipment in working order. To repair the equipment after FAILURE. Maintenance Concept Generations 1st Generation Maintenance Concept 2nd Generation Maintenance Concept 3rd Generation Maintenance Concept • Low Maintenance Effort • Low Maintenance Cost • High Equipment Breakdown • High Maintenance Effort • High Maintenance Cost • Low Equipment Breakdown • Reasonable Maintenance Effort • Reasonable Maintenance Cost • Reasonable Equipment Breakdown Purpose of Maintenance • Attempt to maximize performance of production equipment efficiently and regularly • Prevent breakdown or failures • Minimize production loss from failures • Increase reliability of the operating systems Principle Objectives in Maintenance • To achieve product quality and customer satisfaction through adjusted and serviced equipment • Maximize useful life of equipment • Keep equipment safe and prevent safety hazards • Minimize frequency and severity of interruptions • Maximize production capacity – through high utilization of facility Failure Failure – inability to produce work in appropriate manner o Equipment / machine failure on production floor – worn out bearing, pump, pressure leaks, broken shaft, overheated machine etc. o Equipment failure in office – failure of power supply, airconditioned system, computer network, photocopy machine o Vehicle failure – brake, transmission, engine, cooling system Types of Failure Functional Failure the inability to meet the specified performance standard Potential Failure a physical condition which indicates that the failure process has started Hidden Failure Failure is not apparent until the function is attempted P-F CURVE: The majority of failures do not occur instantaneously but develop over a period of time. Current Maintenance Strategies Fix it when it fails or run until failure Time based (calendar time or running time) Condition based Types of Modern Maintenance Reactive Maintenance (Unplanned Maintenance) • Reactive maintenance is a maintenance strategy in which no preventive measures are done to keep equipment operating as intended by its design. It is sometimes referred to as the “Run it, till it breaks” or “Run to fail” mode. • Under this model, equipment is only given attention and effort when it begins to show indications of failure, so that all maintenance seems to be unplanned. Examples of Reactive Maintenance • The replacement of a light bulb. • Repairing a broken HVAC equipment rather than maintaining it. • Repairing an HVAC unit once data from the unit shows that it is not performing effectively. Advantages of Reactive Maintenance • Reactive maintenance is often perceived as a cost-effective option in the short term. By addressing issues only when they arise, there is a reduction in upfront maintenance expenses. • As maintenance activities are initiated in response to equipment failures, fewer staff members may be required for ongoing monitoring and routine check-ups. Disadvantages of reactive maintenance • Increased Downtime Costs: Unexpected equipment failures result in financial losses and interruptions to business, which lower production levels. • Higher Labor Costs, Especially with Overtime: Overtime is frequently needed for urgent repairs, leading to tight labor budgets and may have an adverse effect on employee wellbeing. • Elevated Repair or Replacement Expenses: Equipment replacement or repair expenses can increase due to more extensive damage caused by delayed responses to problems. Disadvantages of reactive maintenance • Potential Secondary Damage: Reactive techniques may increase overall repair costs by unintentionally damaging other machinery or processes. • Inefficient Staff Resource Utilization: Reactive strategies frequently result in the less-than-ideal utilization of staff resources since workers are assigned in a reactive rather than a proactive manner, which lowers overall productivity. Root Causes in Reactive Maintenance Neglected Basic Conditions: Ignored routine inspections and basic maintenance can lead to reactive breakdowns by allowing minor problems to get worse. Inadequate Skills: One factor that may cause breakdowns is a maintenance crew member’s lack of experience. Reactive conditions can result in more significant damage if faults are not immediately addressed. Non-Adherence to Operating Standards: Equipment stress and failure can arise from deviating from specified operating standards. Reactive reactions are frequently the result of procedures not being followed precisely as instructed. Root Causes in Reactive Maintenance Unchecked Deterioration: Failure to monitor and address gradual deterioration is a common cause of breakdowns in reactive maintenance. Regular inspections are crucial to prevent unchecked wear and tear. Inherent Design Weakness: Breakdowns can be traced back to inherent design weaknesses in equipment. Reactive approaches may highlight issues that could have been addressed during the design phase to enhance durability and reliability. Types of Reactive Maintenance • Emergency Maintenance • Breakdown or Run-to-Failure Maintenance (RTF) Emergency Maintenance • Emergency maintenance is a reactive approach that is initiated in reaction to unplanned failures in equipment or systems. This method addresses immediate issues even though it is expensive—usually three to five times more than preventive maintenance. • The challenges that come with emergency maintenance include extended equipment outages, more impact on output, and higher risks to safety because of hurriedly performed corrective actions. Breakdown or Run-to-Failure Maintenance (RTF) • The objective of a run-to-failure, or corrective maintenance, technique is to repair an item only after it has failed. Deliberate or unplanned, corrective maintenance is the response to malfunctions that may have been avoided with preventative maintenance. • This method works under the assumption that the failure is acceptable, won’t significantly affect the environment or safety, and can’t be prevented economically or technically. • This approach works especially well in situations where there are not many consequences from failure and no immediate need for immediate repairs, such as in general area lighting or smart process instrumentation without trip functionality. • This strategy works well in scenarios where personnel and material costs are not crucial factors and equipment outages have little effect on output. Breakdown or Run-to-Failure Maintenance (RTF) • When selecting Corrective Maintenance as a strategy, however, it is critical to ensure that the failure modes under consideration do not have the potential to escalate into Emergency Maintenance. • Selecting a run-to-failure strategy for machinery that needs to be restored right away following failure would lead to a reactive maintenance setting. It is more costly, inefficient, and unsafe to operate in this reactive environment. • Though a run-to-failure plan may be a good one, it’s important to make wise choices. Avoiding the traps of a reactive maintenance environment requires careful assessment of the possible outcomes and influence on overall operational efficiency. Corrective or Breakdown Maintenance • Corrective or Breakdown maintenance implies that repairs are made after the equipment is failed and can not perform its normal function anymore • Quite justified in small factories where: Down times are non-critical and repair costs are less than other type of maintenance Financial justification for scheduling are not felt Planned Maintenance • The objective of planned maintenance is to minimize downtime and lower total maintenance costs while optimizing the performance of industrial machinery. • The objective of planned maintenance is to maximize efficiency while requiring the least amount of maintenance possible. This method uses a methodical approach in which every worker participates to improve output quality, increase uptime, and lower maintenance costs by continuously optimizing equipment functioning. Planned Maintenance • It includes putting predictive and preventative planned maintenance strategies into action, which improves the general dependability and efficiency of industrial machinery. • The major goal is to create a proactive system that takes care of possible problems before they become more serious, guaranteeing smooth operations and economical maintenance procedures. Preventive Maintenance • The definition of preventive maintenance is actions carried out according to a time- or machine-run schedule that identify, stop, or mitigate a system’s or component’s degradation in order to maintain or increase its useful life by limiting degradation to an acceptable level. Essence of Preventive Maintenance • Preventive maintenance is the foundation of scheduled maintenance, focusing early component identification, replacement, and repair to prevent failures. • This strategy significantly decreases the possibility of large repairs and improves the productivity and reliability of industrial machinery by taking proactive measures to fix minor problems. • Planned maintenance aims for optimal equipment efficiency with a minimal impact on operations. Techniques for Preventive Maintenance • Periodic Reviews: Regular assessments of equipment performance and condition. • Routine Lubrication: Ensuring proper lubrication to reduce friction and wear. • Calibrations: Adjusting equipment to maintain accuracy and optimal functionality. • Inspections: Visual and data-driven inspections to identify potential issues. Costs of Preventative Maintenance • Preventive Maintenance involves higher labor costs for scheduled equipment inspections. However, these expenses are justified by the prevention of major repairs and the reduction in energy consumption from machines operating at peak efficiency. • Outsourcing preventive maintenance services offers a cost-effective solution, providing specialized expertise without extensive in-house resources. • Despite the initial labor expenses, the long-term benefits, such as avoiding major repairs and energy savings, make Preventive Maintenance a financially sound strategy. Outsourcing further optimizes costs, ensuring a balanced approach to maintenance practices and budget considerations. Example of Preventive Maintenance in Action Conveyor Belt Maintenance In a manufacturing setting, conveyor belt systems play a critical role in the efficient movement of materials throughout the production process. To ensure uninterrupted operation and prevent unexpected breakdowns, a proactive preventive maintenance approach is employed. Example of Preventive Maintenance Activities • Regular Inspections: Scheduled inspections of conveyor belts are conducted at predetermined intervals. • Belt Tension Checks: Ensuring the proper tension of the conveyor belt to prevent slippage or excessive wear. • Cleaning and Lubrication: Removal of debris and application of appropriate lubricants to reduce friction and wear. • Replacement of Worn Components: Timely replacement of worn-out or damaged components such as rollers, bearings and splices. Benefits of Preventive Maintenance • Cost Savings: Prevents major repairs, saving on extensive repair or replacement costs. • Operational Continuity: Minimizes downtime by preventing unexpected breakdowns. • Extended Lifecycle: Increases the lifespan of equipment, reducing the need for frequent replacements. • Optimized Performance: Ensures efficient operation and peak performance of equipment. • Energy Cost Savings: Well-maintained equipment operates more efficiently, lowering energy costs. Benefits of Preventive Maintenance • Safety and Compliance: Mitigates safety risks, ensures compliance with regulations, and avoids legal issues. • Enhanced Reliability: Reduces downtime, ensuring consistent production schedules. • Asset Management: Optimizes inventory and ensures availability of spare parts for timely repairs. • Improved Output Quality: Maintains consistent and high-quality output to meet customer expectations. • Positive Reputation: Enhances the company’s reputation for reliability and professionalism in the industry’ Understanding Predictive Maintenance • Utilizing measurements to identify early indicators of system degradation, predictive maintenance changes traditional methods of care and makes it possible to remove or manage causing stressors before major deterioration takes place. • Predictive maintenance is a data-driven, advanced technique that improves overall operating efficiency. In contrast with time-based preventive maintenance, predictive maintenance is based on the machine’s actual state. Examples of Failure that can be addressed by Predictive Maintenance • Unusual sounds coming out of equipment predicts a trouble • An excessively hot electric cable trouble • Simple hand touch can point unusual equipment conditions predicts a trouble a rotating predicts a out many and thus Predictive Maintenance – Definition: • Measuring the beginning of system degradation and the present and future functional capability of components are essential elements of predictive maintenance. It deviates from preventive maintenance in that it uses real-time data instead of predetermined schedules. Predictive Maintenance – Definition: Data-Driven Approach: Predictive maintenance makes use of data from the equipment to map out possible machine breakdowns and identify maintenance needs in a timely manner. Benefits of Predictive Maintenance • Enhanced Product Quality: By resolving any problems before they affect production, predictive maintenance improves the quality of the finished product. • Decreased Catastrophic Failures: Prompt action reduces the possibility of catastrophic events, ensuring ongoing operational dependability. Benefits of Predictive Maintenance • Enhanced Equipment Performance: Proactive maintenance based on real-time data is the key to achieving optimal equipment performance. • Improved Customer Satisfaction: By ensuring dependable and constant delivery of goods or services, predictive maintenance helps to increase customer satisfaction. Reliability-Centered Maintenance (RCM) • Determining the maintenance needs of physical assets within their operational environment is the primary objective of the whole procedure known as reliability-centered maintenance, or RCM. • RCM recognizes variations in equipment design, operation, and susceptibility to various degradation reasons in comparison with traditional maintenance schedules. This strategy organizes maintenance programs by prioritizing and maximizing the use of limited human and financial resources. Basic Philosophy • RCM (Proactive) utilizes predictive and preventive maintenance techniques, incorporating root cause failure analysis to detect and pinpoint precise problems. This approach employs advanced installation and repair techniques, including potential equipment redesign or modification to proactively avoid or eliminate issues. Advantages: • Efficiency: Can be the most efficient maintenance program. • Cost Reduction: Lowers costs by eliminating unnecessary maintenance or overhauls. • Minimized Overhauls: Reduces the frequency of overhauls. • Prevents Sudden Failures: Lowers the probability of sudden equipment failures. • Focus on Critical Components: Allows for the focused maintenance of critical components. • Increased Reliability: Enhances component reliability. • Root Cause Analysis: Incorporates root cause analysis for continuous improvement. Disadvantages: • Startup Costs: May have significant startup costs, including training and equipment. • Visibility of Savings: Potential savings might not be immediately evident to management. Statistical-Based Predictive Maintenance • Uses statistical models and data analysis to predict equipment maintenance needs. • Relies on historical data, patterns, and trends for forecasting potential failures. • Effective for detecting gradual degradation or wear-and-tear not visible through routine inspections. • Analyzes large datasets to predict maintenance based on statistical behavior over time. Condition-Based Predictive Maintenance • Relies on real-time data from sensors during equipment operation. • Measures factors like vibration, temperature, and pressure for continuous assessment. • Enables accurate and timely predictions, facilitating proactive maintenance. • Particularly valuable for equipment with dynamic operating conditions, providing immediate insights into equipment health. MAINTENANANCE SERVICE REPORT MAINTENANCE SERVICE REPORT A maintenance service report is a document that provides a detailed account of maintenance activities performed on a specific piece of equipment, machinery, or system. It is generated by the service provider or maintenance team and serves several purposes, including documentation, communication with the client, and recordkeeping. PARTS OF MAINTENANCE SERVICE REPORT Header: Title: Maintenance Service Report Company Logo/Name PARTS OF THE REPORT • Client Information • Equipment Details • Equipment Name, Equipment Code, Model Number, & Serial Number. • Work Order/Purchase Order Number • Focal Person • Description of the Problem • Pre-Service Evaluation • Corrective Action • Post-Service Evaluation • Notes/Remarks • Prepared By • Acknowledged By Client Representative Equipment code The "equipment code" refers to a unique identifier or code assigned to a specific piece of equipment. This code helps in tracking, managing, and identifying individual equipment units within an organization. The equipment code is typically part of an inventory or asset management system. The "model number" (Model No.) and "serial number" (Serial No.) Model Number (Model No.): The model number is a unique alphanumeric code assigned to a particular design or version of a product. It helps identify the specific configuration, features, and specifications of the item. Manufacturers use model numbers to differentiate between different variants or models within a product line. For example, a company may have multiple models of a printer, and each model would have its own distinct model number. Serial Number (Serial No.): The serial number is a unique identifier assigned to an individual unit of a product. Unlike the model number, the serial number is specific to each unit and serves as a means of distinguishing one unit from another. Serial numbers are often used for tracking purposes, warranty registration, and to help identify and locate a particular item in case of recalls or issues. No two units from the same manufacturer should have the same serial number. MAINTENANCE SERVICE REPORT Description of the Problem: A detailed description of the issue or problem that prompted the maintenance service request. Pre-Service Evaluation: Findings from the initial inspection or assessment of the equipment's condition before any maintenance work is performed. Corrective Action: Details about the actions taken to address and rectify the identified issues, including any replacement or repair of components. MAINTENANCE SERVICE REPORT Post-Service Evaluation: Results of the post-service inspection to verify that the maintenance actions were successful in resolving the problems. Notes/Remarks: Additional comments, recommendations, or remarks regarding the service, any special instructions for the client, or suggestions for future maintenance.
